PROJECT BASED LEARNING

MAKE MY OWN
COMPOSITE MATERIAL
AT HOME

(22 DEC 2020 – 05 JAN 2021)

SUBJECT : CHEMISTRY
CLASS : 4 OPTIMIS
TEACHER : PN SEE YEH LING
GROUP MEMBERS : MAHESH A/L MAHENDRAN (K)
MUDZAFFAR MAHALEEL BIN MURTEDZA

SANJEEVAN KUMARESON
RISHI CHANDRAN

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Table of Content

No Content Page

1 Acknowledgement 3

2 Project Plan 4

3 Abstract 5

4 Materials and Apparatus 6

5 Procedure 7-11

6 Results 12-13

7 Data Analysis and Interpretation 14-15

8 Conclusion and Suggestions for Improvement 16

9 References 17

Acknowledgement

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First and foremost, our deepest gratitude goes to the Headmistress of Sekolah Menengah
Kebangsaan Jalan Empat, Datin Wan Nor Ashikin binti Abu Kasim for granting us the
permission and opportunity to carry out this Project Based Learning. As students, we have
greatly benefitted from the experience and knowledge gained from this project.

We would also like to express our greatest appreciation towards our dedicated Chemistry
teacher, Puan See Yeh Ling for all the knowledge she has bestowed upon us as well as the
never-ending guidance she offered which ultimately led us to successfully completing this
project.

Lastly, to our beloved and caring parents, we cannot thank you enough for assisting us in this
project by guiding us, providing suggestions, as well as financial support. All of these have
greatly worked in favour of improving the outcome of our experiments.

Project Plan

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 Date Duration Activity conducted

26-27 December 2020 1.5 hours Discussion and Planning

28 December 2020 3 hours Purchasing of Materials and Apparatus

1 January 2021 4 hours Production of

Carbon Fibre Reinforced Composite (CFRP)

3 January 2021 6 hours Strength, Flexibility, and Heat Conductivity Tests

of CFRP and Aluminium

4-5 January 2021 6 hours Writing of Report and

Production of Presentation Video

Abstract

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The extensive usage of composite materials has proven that they are the solution to all
predicaments regarding construction materials due to their outstanding performance in
withstanding extreme conditions such as substances on each far end of the pH scale as well as
immense pressure and heat. In addition, some are also known to endure damaging radiation
and most of them to be rather flexible and incredibly lightweight. The objectives of this
project are to replicate Carbon Fibre Reinforced Polymer (CFRP) and compare its properties
with the original components which are carbon fibre (strengthening substance) and epoxy
mixture (matrix substance). This project also performs a comparison between CFRP and
aluminium sheet by conducting three types of tests, namely, strength, flexibility and heat
conductivity. In this project, the “hand lay-up” technique was implemented where a sheet of
aluminium was piled on with four layers of carbon weaves with a coating of epoxy mixture in
between each layer. This process ended with the top layer finally coated with epoxy mixture.
Findings from the project show that CFRP is successfully replicated. When compared with
the properties of the original components, CFRP demonstrated properties such as being
equally lightweight, having high strength-to-weight ratio, high rigidity, resistance towards
corrosion and low electrical conductivity. In terms of strength, flexibility and heat
conductivity, outcomes from the tests conducted reveal that compared to the aluminium sheet,
CFRP possesses greater strength, higher rigidity, and did not conduct heat as effectively as the
aluminium sheet. To conclude, due to its strength, rigidity, and poor conductivity, CFRP can
be extensively applied in various industries such as aerospace, automotive manufacturing and
engineering, and sports equipment.

Materials and Apparatus

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Materials Foam board, hot glue sticks, one 1m x 1m aluminium sheet, mould
release wax (paste form), polyvinyl alcohol, 200g clear epoxy resin and
100g resin catalyst, four plies of 3K carbon fibre weave (two plies of
45° weave, two plies of 90° weave), one 2kg brick, one 3kg brick, one
5kg brick, a candle, a nail

Apparatus A sanding block, packing tape, hot glue gun, brushes (foam brush, acid
brush, disposable brushes), plastic containers (for resin mixing), stirring
rod, weighing scale, popsicle sticks, paper towel, a lighter, a stopwatch

Safety precautions:
Gloves
Safety glasses
N95 Mask

Procedures

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The method used to produce this CFRP sheet is known as “hand lay-up”. Hand lay-up is a
moulding process where fibre reinforcements are placed by hand then wet with resin. In this
project however, no mould was necessary in the making of this CFRP sheet.

Preparations 1. The aluminium sheet was checked to ensure that it was free of any
scratches or markings.
for aluminium
2. A flange was constructed around the aluminium sheet by hot-
sheet
gluing pieces of foam board with a layer of packing tape on top.
Any spaces between the flange and the aluminium sheet were filled
with wax.
3. The aluminium sheet was coated with sufficient mould release
wax. A paper towel was used to rub the surface of the aluminium
sheet until it became smooth, shiny, and no resistance was felt.
This step was repeated to ensure the surface was properly waxed.
4. A foam brush was used to coat the surface of the aluminium sheet
with a layer of polyvinyl alcohol.
5. The aluminium sheet was left to dry for 50 minutes.

Making the 1. A weighing scale was used to measure 20g of resin and 10g of
CFRP sheet resin catalyst and they were placed in two separate containers.
2. An epoxy mixture was prepared by pouring the 20g of resin and
10g resin catalyst into a container. The mixture was then stirred
well.
3. An acid brush was used to coat the epoxy mixture on the
aluminium sheet. The sheet was left to dry for 30 minutes. The
coated layer of epoxy was tested by pressing a finger on it and
observing for an indentation which signified the coating had dried
enough. Duration of this drying stage may differ depending on
atmospheric conditions.

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Making the 4. The first ply of 90° weave carbon fibre was carefully placed on
the aluminium sheet. The carbon fibre weave was generously
CFRP sheet
coated on with epoxy mixture until it was fully coated and no
(Continuation)
dry spots remained. This step was repeated three more times
with the remaining three plies of carbon fibre weave. These plies
were layered on top of one another while alternating between the
45° weave and the 90° weave.
5. The carbon fibre weaves were then left to dry and the epoxy
coats were cured for two days.
6. When the epoxy had fully hardened, the CFRP sheet and the
aluminium sheet were carefully peeled apart from each other.
Popsicle sticks were used to facilitate the process.
7. A pair of scissors were used to cut off excess carbon weaves and
a sanding block was used to smoothen the edges of the CFRP.
Finally, the CFRP sheet was washed with warm water to remove
remaining impurities.

Strength test CFRP sheet Aluminium sheet

1. Two bricks of similar size 1. A sample aluminium sheet with

were prepared as the base to
place the CFRP sheet on.
2. The two bricks were placed
adjacent to each other with a
4cm gap in between.
3. The CFRP sheet was carefully
set above the gap. Both sides
of the sheet were ensured to be
well-placed on the brick for
balance and stability.
dimensions equal to the CFRP was
cut out.
2. The same bricks used in the CFRP
sheet strength test were again
employed as the base to place the
sample aluminium sheet on.
3. These two bricks were placed
adjacent to each other with a 4cm
gap in between.

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Strength test CFRP sheet
(Continuation
4. A 2kg brick was prepared as
)
the weight to be dropped on
the CFRP sheet.
5. Then, the 2kg brick was held
at a height of 5cm above the
CFRP sheet.
6. The brick was dropped onto
the CFRP sheet while making
sure no additional downward
force was applied. The result
was observed and recorded.
Flexibility CFRP sheet
test
1. Two rocks of similar size were
prepared as the base to place the
CFRP sheet on.
2. The two rocks were placed
adjacent to each other with a
4cm gap in between.
3. The CFRP sheet was carefully
set above the gap. Both sides of
the sheet were ensured to be
well-placed on the brick for
balance and stability.
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Aluminium sheet
4. The sample aluminium sheet was
carefully set above the gap. Both
sides of the sample sheet were
made sure to be well on the brick
to ensure balance and stability.
5. A 2kg brick was prepared as the
weight to be dropped on the
sample aluminium sheet.
6. Then, the 2kg brick was held at a
height of 5cm above the sample
aluminium sheet.
7. The brick was dropped onto the
sample aluminium sheet while
making sure no additional
downward force was applied. The
result was observed and recorded.
Aluminium sheet
1. A sample aluminium sheet was cut
out according to the dimensions
equal to the CFRP sheet.
2. The same rocks used in the CFRP
sheet flexibility test were again
employed as the base to place the
sample aluminium sheet on.
3. These two rocks were placed
adjacent to each other with a 4cm
gap in between.
Flexibility test 4. A 2kg brick, a 3kg brick, and 4. The sample aluminium sheet was
(Continuation) a 5kg brick was prepared. carefully set above the gap. Both
5. The 2kg brick was first sides of the sample sheet were
carefully balanced on the ensured to be well-placed on the
CFRP sheet. brick for balance and stability.
6. Next, the 3kg brick was
5. A 2kg brick, a 3kg brick, and a 5kg
added onto the existing 2kg
brick was prepared.
brick, thus making the total
6. The 2kg brick was placed on the
weight on the CFRP sheet
sample aluminium sheet.
5kg.
7. Observation was recorded after the
7. Finally, the 5kg brick was aluminium sheet collapsed under
put on top the 3kg brick and the weight of the 2kg brick.
the 2kg brick. This makes
the total weight on the CFRP
sheet to be 10kg.
8. After the CFRP sheet was
able to withstand the weight
of all three bricks, the
observation was recorded.

Heat CFRP sheet Aluminium sheet

conductivity 1. A sample aluminium sheet was cut
1. Two bricks of similar size
test
out according to the dimensions
were prepared as the base to
equal to the CFRP sheet.
place the CFRP sheet on.
2. Two bricks of similar size were
2. These two bricks were placed
prepared as the base to place the
vertically and adjacent to each
sample aluminium sheet on.
other with a 4cm gap in
3. These two bricks were placed
between.
vertically and adjacent to each other
3. A stopwatch was prepared to
with a 4cm gap in between.
record the time taken for the
4. A stopwatch was prepared to record
nail to fall off the CFRP sheet.
the time taken for the nail to fall off
the sample aluminium sheet.

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Heat CFRP sheet Aluminium sheet
conductivity
test 4. A candle was lit using a 5. A candle was lit using a lighter and
(Continuation)
lighter and a few drops of a few drops of candle wax was
candle wax was melted onto melted onto the bottom side of the
the bottom side of the CFRP sample aluminium sheet, near its
sheet, near its circumference. circumference. A nail was placed
A nail was placed into the into the melted wax and it was
melted wax and it was held held in place until the wax froze.
in place until the wax froze.
6. The lit candle was placed in
5. The lit candle was placed in
between the two bricks. Measures
between the two bricks.
were taken to ensure that the flame
Measures were taken to
did not extinguish.
ensure that the flame did not
7. The sample aluminium sheet was
extinguish.
carefully placed on the flame with
6. The CFRP sheet was
the side that had the nail attached
carefully placed on the flame
to facing downwards. The
with the side that had the nail
stopwatch was started at the same
attached to facing
time.
downwards. The stopwatch
was started at the same time. 8. The candle flame was ensured to
7. The candle flame was be exactly at the centre of the
ensured to be exactly at the sample aluminium sheet.
centre of the CFRP sheet.
9. The sample aluminium sheet was
8. The CFRP sheet was left to
left to be heated and the time taken
be heated and the time taken
for the nail to fall off was
for the nail to fall off was
recorded.
recorded.

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Results
CFRP sheet

Front side view Rear side view

Data of strength, flexibility and heat conductivity tests

Strength test
Type of sheet Result of test
Did it withstand Description
20N drop test?
Aluminium sheet ✕ Aluminium sheet
collapsed and its
shape was deformed
upon impact of the
brick.
CFRP sheet ✓ CFRP sheet did not
collapse and its shape
maintained the same
upon impact of the
brick.

Flexibility test
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 Type of sheet Result of test
Did it withstand: Description
2kg 3kg 5kg
brick? brick? brick?
Aluminium sheet ✓ ✕ ✕ Aluminium
sheet collapsed
under the
weight of the
first brick
(2kg).
CFRP sheet ✓ ✓ ✓ CFRP sheet
was able to
withstand the
weight of all
three bricks
(10kg).

Heat conductivity
test Type of sheet Result of test
Was the nail still Description
attached to the sheet
after 30 seconds?
Aluminium sheet ✕ The wax holding the
nail melted rapidly
and the nail dropped
after 15.5 seconds of
exposure to a heat
source.
CFRP sheet ✓ The wax holding the
nail did not begin
melting and the nail
was still attached
after 30 seconds of
exposure to a heat
source.

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Data Analysis and Interpretation

Name Carbon Fibre Epoxy Mixture Carbon Fibre

Physical Reinforced
Properties Polymer

Chemical formula C C21H25ClO5 -

Appearance Black solid Clear liquid Clear and shiny

black solid
Density (g/cm^3) 1.95 1.8 2.0

Malleability Non-malleable Non-malleable Non-malleable

Melting point (°C) 3652-3697 Reverts to liquid state at ≤1500

(varies for different 60-350
types of (varies for different
carbon fibre) epoxy mixtures)

Boiling point (°C) 4200 - -

Freezing point ≤-184 Cures between -40

(°C) 1-60
(varies for different
epoxy mixtures)

Solubility Insoluble in water Soluble in organic Insoluble in

solutions water

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 Comparison
of properties

Carbon Fibre Aluminium

Reinforced Polymer Sheet
2.0 Density (g/cm^3) 2.7
≤1500 Melting point (°C) 660
937 Specific heat 904
capacity
(J kg^-1 °C^-1)
Insoluble in water Solubility Insoluble in water

Poor conductor Electric Good conductor

conductivity
Non-malleable Malleability Malleable
Not brittle Brittleness Not brittle

Based on the comparison above and the tests that we conducted, it is proven that CFRP is
superior compared to aluminium in the sense where CFRP outperformed aluminium in our
tests. In the strength test, CFRP withstood a force of 20N whereas aluminium collapsed when
exposed to the same force. In the flexibility test, CFRP held a total mass of 10 kilogrammes
whereas aluminium gave away after holding only 2 kilogrammes. In the heat conductivity
test, CFRP proved to be a poor heat conductor unlike aluminium which conducted heat well.
This is deduced from the fact that the wax connected to CFRP did not melt even after 30
seconds of exposure whereas the wax connected to aluminium melted at 15.5 seconds. To
conclude, CFRP has a wider range of applications than aluminium due to its strength, rigidity
and thermal properties being far superior than its competitor.

Uses of CFRP include aerospace and aviation where it is used as the fuselage of the aircraft as
well as the fan blades of the engines, maritime vehicles where it can be used as the hull of the
vehicle. In automotive engineering, it can be incorporated into various parts of the body of the
vehicle. In terms of civil engineering, it can be incorporated in the retrofitting process, as well
as in the design of sports equipment such as badminton racquets and the frame of bicycles.

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Conclusion and Suggestions for Improvement

The objectives of this project are to replicate Carbon Fibre Reinforced Polymer (CFRP),
compare its properties with the original components (which are carbon fibre and epoxy
mixture), and finally compare between CFRP and aluminium sheet by conducting three types
of tests, namely, on strength, flexibility as well as heat conductivity.

The key findings obtained from the project show that CFRP is successfully replicated.
Findings also reveal that CFRP’s properties are lightweight, possess high strength-to-weight
ratio, demonstrate high rigidity, resistant to corrosion and have low electrical conductivity.
When compared to aluminium, outcomes from the tests conducted show that CFRP possesses
greater strength, higher rigidity but does not conduct heat as effectively as aluminium.

Application of CFRP use would include aviation, automotive and marine engineering, civil
engineering, as well as the material for sports equipment.

Lastly, it is also suggested that future projects involving CFRP could try to use a higher
quality of epoxy that can endure a higher range of temperatures (before reverting to liquid
state). Other than that, more layers of carbon fibre weaves can be introduced to the production
of CFRP to increase the integrity of the final product. Moreover, a different type of weaving
such as 6K or 12K grade carbon fibre can be incorporated to achieve different attributes of the
CFRP (such as being stiffer).

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References

 Anonymous. “Carbon fiber reinforced polymer”. Internet:

https://en.wikipedia.org/wiki/Carbon_fiber_reinforced_polymer, January 4, 2021.
 Anonymous. “Carbon fiber”. Internet:
http://compositesmanufacturingmagazine.com/tag/carbon-fiber/, January 4, 2021.
 O. Derviz, S.G. Mustafa, and C.K. Abdullah. “Carbon Fiber Reinforced Composite
(CFRP) Composite Materials, Their Characteristic Properties, Industrial Application
Areas and Their Machinability. Internet:
https://link.springer.com/chapter/10.1007/978-3-030-39062-4_20, January 4, 2021.
 Anonymous. Industrial and Manufacturing. Internet:
https://link.springer.com/chapter/10.1007/978-3-030-39062-4_20, January 4, 2021.

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